An Intelligent Hybrid Manufacturing System for FDM Surface Defects Monitoring with Industry 4.0
Bibliographic record
Abstract
Additive manufacturing (AM) and machining in a single machine colloquially known as Hybrid manufacturing help to produce customized and complex products without assembling including greater design freedom and reduced material wastage. A CNC-based grinding mechanism is introduced in the same system to overcome those defects and enhance the quality. To increase productivity and improve product surface quality, evolving additive manufacturing demand and finishing subtractive processes must be combined on the same platform. For the additive manufacturing method, Fused Deposition Modeling (FDM) has been employed, and a grinding operation can be performed for surface finishing. A camera module is used to capture surface images for defect detection such as stringing, rashing, and surface cracking after the AM process. Convolutional Neural Network (CNN) is applied to the captured image for the defect detection process. If the CNN analysis reveals any surface defects, a grinding operation will be performed on the surface for better surface quality. The architecture has provided a platform to collect data from the image captured by the camera module for evaluating and identifying surface defects using CNN. CNN model provided 89% accuracy for surface defects detection. As a result, the CNC grinding operation can be done on that particular surface of the product for smoothing the partially roughened surfaces. Therefore, this study demonstrates to improve the surface quality, reduce cycle time, set up time reduction & improve the product's sustainability. The proposed approach of a hybrid manufacturing system also provides a basic framework to increase efficiency, reduce downtime, increase efficiency, improve end part consistencies of the product as a consequence of post-processing & defect detection in the same system, and enable I4.0
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How this classification was reachedexpand
Full frame machine prediction
Teacher imitationNot calibrated prevalence, not ground truth. Human validation pending. The Gemma side is a direct model label for every work in the frame, read from the title-only record. The Codex side is a classifier learned from the 10,348 direct Codex labels and calibrated to design-weighted sample rates; fields without enough sample support carry no Codex call. Candidate is the union of the two sides; consensus is their intersection. These outputs are machine_predicted_unvalidated and are not human labels.
Distilled classifier scores by category (both heads)
| Category | Codex | Gemma |
|---|---|---|
| Metaresearch | 0.001 | 0.000 |
| Meta-epidemiology (narrow) | 0.001 | 0.000 |
| Meta-epidemiology (broad) | 0.001 | 0.000 |
| Bibliometrics | 0.001 | 0.001 |
| Science and technology studies | 0.000 | 0.000 |
| Scholarly communication | 0.001 | 0.001 |
| Open science | 0.002 | 0.001 |
| Research integrity | 0.001 | 0.000 |
| Insufficient payload (model declined to judge) | 0.005 | 0.001 |
Machine scores (provisional)
The two teacher heads of the student model, read on this work. A score orders the frame for review; it never asserts a category, and the validation status ships verbatim with every row.
Baseline scores from an immature model (maturity gate not passed, 7 training rounds). Scores rank; they never assert a category.
score_only:v0-immature-baseline · verbatim from the scoring run: score_only means the number may rank works, and no category label ships from itClassification
machine, unvalidatedMachine predicted; a candidate call from one source (direct Gemma or distilled Codex), not a consensus.
How this classification was reached, model by model and score by score, is at the end of the page under "How this classification was reached".